Internal combustion engine fuel injector



Sept. 29, 1942.

o. Fuse/gpo 2,297,399 INTERNAL COMBUSTION ENGINE FUEL INJECTOR Fied Nev. 21, 1939 asheets-shee't 1 43 1o 14 9 F|G 'ld FIG. 1B,

s2 As711125 y om@ @usw-m5 Sept. 29, 1942.

o. FuscALDQ- INTERNAL COMBUSTION-ENGINE FUEL INJECTOR Filed Nov. 21, 1939 2 Sheets-Sheet 2 p AFIG. 2

` @zum qmla 7.. ...PM 1 Ll Patented Sept. 29, 1942 INTERNAL COMBUS'l'irIOg ENGINE FUEL INJEC 0 Ottavio Fuscaldo, Milan, Italy;

Aliealrperty Cust November 21, 1939, In Italy January 20, 19 9 Application vested in the seral No. 305,419

s claims. y. (ci. 13T-139) This invention is for improvements in or ref lating to internal combustion'engine fuel injectors and is concerned with an electromagnetieally operated injector of the type comprising a magnetic means or solenoid working in opposition to a spring for opening and closing the valve. In the illustrated form is shown, in

combination, a movable armature or core, preferably subject to a'yielding control, solid with a valve stem and valve controlling the fuel outletnozzle, an electric winding for creating a inag netic flux in `a magnetic circuit for periodically attracting the armature, thus closing the magnetic circuit, the magnetic circuit being formedv entirely of magnetic material and the movable armature being operable independent of the action (pressure, viscosity, etc.) of the liquid fuel.

An electromagnetically controlled injecting system may comprise an injector or a number of injectors of the described type, a current distributor, a fuel-feeding apparatus delivering to the injector or to the injectors and "a fuel-flow controlling apparatus. The eiciency of th system depends entirely on that oi the ejector, es-

pecially at high speeds.

The main object of the invention is to provide highly elent electromagnetic injectors, which entirely -solve the faults of injection systems hitherto employed.

'Ihe electromagnetic injector has a distinct advantage over hydraulically or mechanically controlled injectors, avoiding the inherent defects thereof. It should, thereforef operate perfectly In order that the injector should maintain correct fuel delivery for a long period of operation, it is necessary (f) that-the friction and percussion surfaces ,should be very hard and that (y) the innerl parts in contact with the fuel should be stainless.

The injector should also be. (h) readily de-y mountable and adjustable by mechanics of aver- .age skill, without requiring the yservices of a specialist, and, finally, the construction should -be of such a nature (i) that all the injectors built by mass production have identical characteristics Thus, several injectors of a single multi-cylinder engine have lpractically equal fuel deliveries at all engine speeds.

In rorder that the invention may be readily understood an example thereof will be described with reference to the accompanying drawings, in which:

Figs. l'and 1b together constitute a longitudinal sectional view on` an enlarged `scale ofan injector constructed according to the invention;

Figure 2 is a plan view of Figs. la and 1b on4 a reduced scale;

Figure 3 is a cross section along the line 3 3 of Figures 1h and 2;

Figure 4 shows an enlarged end view of the guiding '-'device of the valve;

with high frequency injections, at very short in-v tervals, as required by modern two-stroke. and

four-stroke engines, maintain its characteristics` for long periods of operation, have such standard'designs of parts as allow an easy reproduci tion on a manufacturing scale, and be capable of easyoperation and maintenance.

In order that the electromagnetic injector can operate with high frequencies and exactly predetermined injections, even ivn a. very short time and requiring the lowest possible, current, it

t should: v

(a) Be very highly efficient (b) Have very light moving parts;

(c) Have moving parts `capable of moving very rapidly within the compressed fuel in which it is immersed;

(d) Have very small friction between the moving parts and the xed parts;

(e) Have a very 'short valve stroke combined with a tight closure of the nozzle.

Figure '5 is an end elevation of the movable amature or core;

Figure 6 is a cross sectional view of a wing or spokeof the armature along the line 6 6' of Figure 'I illustrates a modified construction .of

the valve.

nReferring to the drawings, .the magnetic cirof an injector according s to the invention comprises a housing wall or shroud I, end extensions or, flanges 2 and 3 therefor, a solenoid coil or winding-30, a central and preferably fixed armature or core ll adjustably shiftablefor adjusting the lift or travel` of a valve l0, and a ring 5 (moving armaturelfast s tem`9'of the valve. Y

The parts forming the magnetic circuit of the electromagnet are of very pure iron, having high magnetic permeability and very small coercive 'force and hysteresis, since the iron must magneis energised and tize rapidly as soon as the coil must` demagnetize as rapidly and as completely as possible ,when the'exciting current circuit is broken! Y V The magnetic-circuit is indicated in Figure 15 .by arrows 6, the, onlygap therein being in the axial end-clearance .'I between the xed armaupon or rigid with ture 4 and the moving armature 5, which clearance corresponds exactly to the stroke of the valve.

When the coil is energised, the movable armature i is attracted by the iixed armature 4 so that the end clearance is reduced to zero and the magnetic circuit closes. The side or radial clearance between the moving armature 5 and flange 2 guiding it, although minute, is a harmful gap which is required, however, for permitting the free shifting motion of sliding armature 5. This gap should be as small as possible, both for reducing to the utmost the reluctance of the magnetic circuit, by reducing the resistance to the,

magnetic flux through the thin film of fuel filling the whole cavity of the injector, and for reducing to a minimum the diierence in thickness of the thin film at diametrically opposed poin With regard to condition (b) concerning 'the' at the end of the stroke caused either by abutment against the fixed armatureor against the valve seat I'I. In terming the thrusting device I I a spring, this is intended to cover any analogous elastic or resilient device operable to restore the clearance between the xed armature 4 and j flange 3, but it can be reduced to a negligible value, since the armature 4 is not intended to slide freely as is the ring 5, but should only be thrust from the outside with a slight movement and only when adjusting the stroke of the valve.

The moving armature 5 is ring-shaped as is preferably also the end of the fixed armature 4 facing it. This eifects a concentration of the magnetic ux on the two poles facing each other, causing them to saturate magnetically so as to increase to the utmost the attractive power of the electromagnet.' Moreover, as the hub 8 connecting the ring amature i to the stem `9 of the valve I0 is made of non-magnetic material, for example bronze, and, for reasons stated hereinafter, since the stem 9 and the spring II are of tempered steel, this will prevent magnetic flux from dispersing in any great quantity in the stem and spring. On the contrary, the resilient spring II bears in opposition to the attractive force with its smallest convolution at the conical end thereof seated on the hub 8 projecting within the cavity of the hollow xed amature 4.

As distinguished from the inside members 4 and 5 of the electromagnet, the enclosing wall I and anges 2 and 3 are very thick so as easily to collect the lines of force, which, otherwise, would mainly tend to pass through the outer air, tliirus increasing the reluctance of the magnetic c cui Flanges 2, 3 have extending between them,

armature 4, the threads might in time be stripped because of adjustment, pure iron being very sott. If, however, it were matie` of steel, it would magnetize permanently and thereby impair the operation o'i the electromagnet.

The above precautions satisfy the condition (a) relating to magnet:

high emciency oi the electro-A the seat of the valve which enters into the engine' as far as requiredto. bring the injectionv nozzle into the most convenient position in the combustion chamber according to the prevailing circumstances. s

For this purpose the moving parts have a predetermined length and, in order to make this entity as light as possible, the connection of the valve I0 with the hub 8 which supports the armature 5 is formed by a very thin stem 9. Experience has shown that a solid rod of tempered steel is preferable for light weight and dimensions, consistent with resistance and rigidity. A hollow stem would be inadequate, due to the very slight forces it has to withstand.

Stem 9 is pressed into the bronze hub 8 and into the valve I0, the latter also being made of tempered steel; in order to increase the factor of safety, soft solder is added at the points I4 and I5. i

As an alternative, as shown in Figure '7, the

valve and stem can be made in a single piece,

turned or ground out of a small rod.

The armature 5 is forced'on to the wings or spokes of the. hub or spider 8l and, for greater safety, is soft-soldered thereto at points I6 corresponding to the outside edges of wings I8.

',The moving parts must, in accordance with condition y(c) be capable of moving veryerapidly and ata high frequency within the fuel under pressure which fills the chamber inside of the injector. Around hub 8 therefore are provided large free passages for the liquid between the two ends and the hub is small and displaces theleast possible liquid without turbulence.

For the same purpose the inside left edgesof the armature are chamfered, the wings i8 on the hub 8 are very thin and have tapered ends as shown in Figures 5 and 6, the hubl 8 has tapering ends, the soldered parts I4 and I5 formingV fillets, and the pitch of the spring II is equal to or even greater than the thickness of the wire.

It is also preferable that the fuel inlet into the injector should be between the moving armature and the nozzle so as not to force the fuel through the armature in its flow towards the nozzleas such a passage, under. violent impulses, would slow down the opening of the valve guide is tapered towards the nozzle and all the `edges of the valve and of the nozzle are rounded out.

Condition (d) concerning reducing as much as possible the friction between .the moving parts and the xed part is required not so much for reducing wear,'as for obtaining a greater speed in opening and closing the nozzle, equal attractive force of the electromagnet and pressure of the spring being assumed.

-Among the many causes of friction, neglecting that due solely to the weight of the moving parts and to faulty design or workmanship, are:

1. An uneven distribution of the magnetic flux around the moving armature 5 of the electromagnet, due to excessive clearance or to the pressure of unsymmetrical holes or recesses in the shroud l. In order to avoid the latter cause, the connecting hole or part for the entrance of the fuel by bronze pipe I9 is placed diametrally opposite to the recesses required for mounting the current supply terminal 2li (which terminal block is motnted von insulating material) so as to provide compensation or balancing of metal.

2. The diiculty of obtaining proper and perfect alignment between parts A and B'of the injector. This diiculty is overcome by guiding the moving part of the injector at the end of the parts A and B, by means of guides formed in the very short portions 2l and 22, so short that they can assume the necessary inclination even when the clearances in the guides are very small. Notwithstanding the inclined position the invention secures the tightness of the valve closure as will be described hereinafter. A

3. The side thrusts against 'the stem 9 caused by the fuel entering by impulses in the injector from the pipe I 9. Such blows are avoided by causing the fuel to enter firstly into an annular chamber 23 and then from the latterv into the central cavity of the injector through an annu.-v lar passage or slot 24, coaxial' with the stem/T9.

4. Imperfections in the spring Il; when not properly centered on armatures 4 .and 5 the spring does not keep straight enough and the bearing ends thereof are not parallel and square with the centre-line, or when the hardening is not uniform etc., side pressures in the armature 5 may arise. To overcome such possible diiiiculties centering devices are provided on the hub 8 by having stem projecting, and on -the armavture d by means of a bronze plug or seat 25,

the latter also contributing to a certain extent to the insulation of the spring I I from the armature 4. The left hand end of the spring being conically shaped, it bears centrally on the hub 8 so as to compensate for unavoidable imperfections in construction.

5. The use of Jthe same `soft metal' (soft iron) for thev flange 2 and the armature 5.- This would tend to cause seizure after a short period of operation. To prevent this, the surfaces are chromium-plated, this having further advantages set forth below.

'l'he coeflicient of friction of chromium against chromium being very low, the ability of the rmature 5 to slide easily within flanges 2 is improved.

The requirement (e) of a short valve stroke and a tight closure of the valve are achieved, according to the invention, in the following manner. The tightness of the valve closure should be ensured'even when the valve is slightly inclined due to imperfect alignment of parts A and B of the injector. To this end, whilst the guide- 2l is placed very near to the seat of the valve, for reducing the friction, the seat itself is shaped as a hollow spherical cup, the spherical centre of which-is preferably placed about half-way along the length of the guide 2i on the centre-line of the injector. The seat or the annular bearing 26 for the valve I0 has a rather small slope which is particularly favourable for effective valve lift, as it appears clearly that with the sarneeffective section of the nozzle the lift of the valve is less the smaller is the slope of the seat thereof.

A further advantage of the spherical seat is that it is possible to grind it'true and polish the surface by the same methods as are employed in preparing glass lenses, so as to avoid circular' grooves concentric with the nozzle.

With regard to condition (f) concerning the employing very hard frictionand percussion surfaces.

' and B is lparticularly convenient yboth with re- For the friction surfaces, the valve in fthe guide 2| is` made of tempered steel and the guides of hard gun-metal; the guide 22, armature 5 and ange 2, being of very soft iron, are surfacehardened by an electro-plated layer of chromium, avoiding any heat treatment which might change the good magnetic properties of the iron.

As to the percussion surfaces, they are made of tempered steel for valve I0 and for the nozzle piece Il. sufficient for maintaining them in good conditions within "safe practical limits. The mutually facing annular zones or ends of the soft iron armatures or core parts d and 5 are hardened by an electro-plated layer of chromium deposited with vsuch care as to prevent it from peelingoi under continual percussion. To prevent the y should only be unattacked by the usual fuels, the.

parts kof tempered steel and of bronze are practically corrosionless." On the contrary, the iron surfaces of the shroud i andof the flanges 2 which arenot chromium-plated, as stated above, areiprotected with a light electro-plating. 4

The design of the apparatus in two parts A gard to' unified mass production and with regard to ease in assembling and fitting and in adjusting etc. according to conditions (h) and (i) Part B can be unscrewed from part, A and then screwed-on again, when required for .cleaning, without changing the'original adjustment of the valve stroke; `the screwing on again of the parts should stop at a point previously markedo, and any errors thereby incurred are quite negligible.

A washer 29 inserted between the two parts A and B is made of a material having a hardness equal to that of annealed copper, thus excluding the use of any plastic material.

The adjustment of the stroke of the valve (axial clearance 'Il is obtained by screwing in or out the armature 4 relatively to the cover I3. For fixing the armature 4 in a desired position after adjustment, a nut 31 threaded in to the projection 38 of cove'r I3 is tightened. This nut has a conical extension surrounding the slotted conical extension '38 of the cover or cap I3, so that tightening the nut locks the threaded extension of the adjustable core 4 within the cover, without causing any radial pressure. This is v ry important for correct adjustment since otherwise a simple locknut or double nut screwed on to the armature 4 would cause a longitudinal movement of the armature, corresponding to the eventual clearance existing between the threads; while a lateral set-screw would shift the armature eccentrically. l

It is clear that the above described adjustment .can-be brought about from the outside, even during the operation of the engine and by any known control means.

The nozzle piece I'I is fixed onthe nozzlecarrier or chamber wall 21 by means of a union or nut 28 and can be easily removed, if necessary, forA cleaning, and it can be replaced in position without altering the valve stroke and it can also readily be changed for another piece when required to alter the diameter of the injecting nozzle or orifice member 43. I

The bobbin or spool formed by the tube I2 and end extensions 2 and 3 carries the winding 30 of insulated wire. This coil has on the outside `thereof Vtwo thin strips 3| of silver or of silvered copper or the like, acting as contacts, to which are soldered the two ends of the winding conductor. The conducting springs 32, preferably of silvered false-gold, fixed to the two current input terminals 33 bear against the two contact strips 3 I. v

The two terminals 33 are incorporated in an insulating block 20 secured to the shroud by a central screw 35.

The injector may be xed to the engine by means of two brackets, not shown, entering into the lateral slots 44 of the shroud, seen in Fig. 2.'

The bobbin, as stated above, is secured within the shroud by means of the threaded cover I3. A gasket 40 of any desired plastic material is placed between the end wall 21 of the bobbin and the interior end of the shroud to prevent the fuel from entering into the chamber of the bobportance in order that during adjustment the core 4 can slide in a straight line. For this purnumber of turns, length, material and heat treatment) are, as stated above, very important inasmuch as they must be the same for all the injectors of a single engine, provided that in all injectors the distance between seats 8 and 25 against which the springs abut is maintained constant. It is preferable, as proved by experience, to use tempered steel wire for the springs because the eillciency of springs of stainless steel or phosphor bronze is reduced due to the fatigue stresses arising from the high frequency of operation and consequent vibrations.

The springs; should have a low flexibility so that the thrust on the valve is light when the valve is closed (considering that the pressure of the fuel assists the valve to close) and becomes strong when the valve is open. Thus the opening begins rapidly when the force of attraction on the armature is slight due to the great air gap, the spring II contributing to braking the strong attraction at the end of the stroke` and later bin, while a pin 4I projecting from end wall 3 i' nowing out along the outside of core 4, but allows the core to be screwed in and out for adjustment. The perfect coaxiality of the shroud I of the cover Il aad of the bobbin is of paramount imfacilitating the severance of the moving armature from the fixed armature, when on switching oi the current the residual magnetism of the latter and its 'magnetic hysteresis, which always exist to a slight degree, tend to retain the armature. I

In this way very quick opening and closing actions of the valve are ensured and very high irequencies of performance are possible.

Having now described my invention and how the same may behpracticed, what I claim asmy invention is:

-1. An internal combustion engine injection apparatus of the kind recited having an elongated liquid r-fuel pressure chamber and an immersed valve and stem reciprocable longitudinally within the chamber with a short stroke of retraction against resilient return,I in combination with electromagnetic means operable to retract and then release the valve stem, the same comprising a solenoid coil with a two-part ironcOre therein. oneu core part constitutingan annular head fast on said stem and movable in the liquid therewith and of open construction for free liquid flow whereby it may shift without substantial obstruction from the liquid, the stem and head by their short stroke being adapted to leave a short magnetic gap between the two core parts in one position and to close such gap in the other position, and other iron parts constituting with said core parts a Amagnetic circuit disposed -around said coil, said other iron parts comprising an outer housing wall, and.inward extensions therefrom to the movable and the other core part respectively; said outer wall having a longitudinal extension beyond the movable core part formed with a liquid inlet, whereby a substantially stagnant space is left between said inlet and the core parts.

A 2. An injector as in `claim 1 and wherein the V params of the kind recited having a liquid fuel pressure chamber and an immersed valve stem shftable longitudinally within the chamber with a short stroke; a spring thrusting upon the stem to advance it, and electromagnetic means operable to retract and then release the valve stem, the same comprising a solenoid coil with a twopart iron core therein, both core parts extending 'bodily within the coil; one core part constituting an annular head or sleeve fast on said stem and movable in the liquid therewith and of open construction for free liquid ow whereby it may shift without substantial obstruction from the liquid, and the stem and head by their short stroke being adapted to leave a short magnetic gap between the two core parts when the stem is advanced and to close such gap when in retracted position, such gap being located in the space inside the solenoid coil; and other iron parts constituting with said core parts a magnetic ilux circuit disposed around said coil, said other iron parts comprising an outer housing wall, a first inward extension therefrom within and through which the movable annular core part extends and is guided, and a second inward extension between the wall and the other core part; and said stem thrusting spring being a compressed spring to advance it,v and electromagnetic means operable to retract and then release the valve stem, the same comprising a solenoid coil with a twopart iron core therein, both parts extending into A the space within the coil; one core part being longitudinally movable and comprising an annular sleeve of iron on said stem and shiftable in the liquid therewith, and of open construction interposed between the two core parts thereby acting to advance the movable core part and open the magnetic gap but adapted to be overcome by the magnetic pull of the solenoid.

4. An internal combustion engine injection apparatus of the kind recited having a liquid fuel for freeliquid `flow whereby it may shift without substantial obstruction from the liquid, the stem carrying a non-magntic hub fast thereon and an open web between the hub and iron sleeve, and the other or fixed core part being of annular or sleeve construction at least at its end adjacent to the annular movable core part, the stem and head by their short stroke being adapted to leave a short annular magnetic gap inside the coil and between the two core parts in one position when the stem is advanced and to close such gap in the retractedposition; and other iron parts constituting with said core parts a magnetic fluxcircuit disposed around said coil, said other iron parts comprising an outer housing wall, afirst inward extension therefrom within which the movable core part or annular stem head isguided, and a second inward extension between the wall and the other core part; and said stem advancing spring being a compressed spring interposed between the two core parts acting to thrust the movable core part and open the magnetic gap but adapted to be overcome by the magnetic pull of the solenoid, said spring having its ends seated respectively on said movable core sleeve hub and within the annular, fixed core part.

5. An injection apparatus as in claim 4 and wherein the movable sleeve hub is prolonged beyond the movable sleeve and beyond the core gap and protruded into the space within the fixed Pressure chamber and an immersed valve stem*- core sleeve, whereby the steel spring, seated on said hub -and within the xed sleeve, is located wholly inside thev ixed core sleeve and removed from the magnetic gap; the spring being helical and conically tapered, with its smaller end seated on said hub.

O'I'IAVIO FUSCALDO. 

